Method and apparatus for plastic duct bank manufacture

ABSTRACT

A method and apparatus for manufacturing a duct bank comprising the steps of loading a frame with a series of templates, positioning the frame adjacent a pipe extruder, aligning a set of a plurality of holes with a die of the pipe extruder, extruding a pipe of a first length into the set of holes, repeating the steps of aligning and extruding for each set of holes, thereby forming the duct bank, banding the duct bank, and removing the duct bank from the frame.

FIELD OF THE INVENTION

The field of the invention relates to the manufacture of plastic pipe.In particular, the field of the invention relates to a method andapparatus for the prefabrication of plastic duct bank.

BACKGROUND OF THE INVENTION

The transmission of electrical power, data, and telephone communicationsbeneath buildings is carried out through wires and cables installedinside conduit pipes. The pipes are often assembled into bundles knownas “duct banks.” Duct banks consist of multiple sections of ductingarranged in a rectangular pattern and held in position by “templates.”The templates are generally flat rectangular spacers each having apattern of holes through which the pipes are inserted.

Duct banks are typically assembled on site or transported to aconstruction site where they are installed. During installation eachduct bank is loaded into a trench along a predetermined route. Each ductbank is then joined with other similar duct banks with couplings, sealedand encased in concrete.

In the prior art, duct banks are assembled on the job site either in thetrench or above ground near the trench. Typically, a first set ofworkers holds a set of templates at a predetermined angle and at thecorrect spacing to position and hold the ducts in place. A second set ofworkers positions each pipe in a set of corresponding holes in thetemplates by sliding it through the holes. The process islabor-intensive, dangerous, and subject to frequent interruption duringassembly in order to provide realignment of the templates and undojamming of the pipes.

The prior art has attempted to solve some of these problems. Forexample, U.S. Pat. No. 3,606,395 to Salerno, et al. discloses a methodand apparatus of laying underground cables using preformed conduitsections. The preformed conduit sections are rectangular blocks havingfour longitudinal holes forming conduit pipes. The preformed conduitsections are aligned end to end to form four continuous ducts. However,the block conduit sections in Salerno require excess material tosurround each conduit in order to form the conduit section. This excessmaterial requires additional raw materials, which increasesmanufacturing costs.

U.S. Pat. No. 3,711,127 to Raffa discloses a closure to arrange conduitmembers into a duct bank. The closure includes a horizontal base,upright side walls formed integrally with the base, longitudinal sidewalls, and upright members attached to the base having a generallyrectangular shape adapted to align and support conduit members. Theupright side walls have tapered sleeves sized to align and support theconduit members. The closure is sealed and filled with an inert gas toimprove insulation and heat dissipation. However, Raffa requires the useof a housing to encase the duct bank and inert gas to fill the housing,thereby making the arrangement expensive to manufacture and assemble.

U.S. Pat. No. 5,605,419 to Reinert discloses a method for assembling andinstalling duct banks. The duct banks are assembled with upright plasticgrids having apertures sized to axially receive conduits. The grids arespaced apart along the length of the conduits. Spacers are installed ingroups of four, onto conduit members, one on each corner of the crosssection of the duct bank. Wooden supports are placed across the conduitsto support the duct bank. However, the method requires the duct bank tobe assembled at the jobsite, which requires additional workers andexposes the workers to unnecessary dangers, thereby increasinginstallation costs.

The prior art fails to disclose or suggest a method and apparatus forprefabricating duct banks at the point of pipe extrusion. The prior artalso fails to disclose an automated method of assembly of duct banks.Therefore, there is a need in the prior art for a method and apparatusfor manufacturing and preassembling a duct bank that reduces time andlabor costs and increases worker safety.

SUMMARY

In a preferred embodiment, a method for manufacturing a duct bankcomprising the steps of providing a set of rigid templates, each of thetemplates comprising a set of patterned holes; providing a frame havinga set of supports for the templates loading the set of supports with theset of templates; positioning the templates to align a set of holes;positioning the frame adjacent an extrusion machine, the extrusionmachine having a coaxial extrusion die, a cooling section, and a cutter;aligning the set of holes with the extrusion die; extruding a pipe of afirst predetermined length into the set of holes; repeating the steps ofaligning and extruding until a pipe is extruded into each set of holes,thereby forming the duct bank; banding the duct bank; and removing theduct bank from the frame.

In a preferred embodiment, the step of extruding a pipe of a firstpredetermined length into the set of holes includes the steps of coolingthe pipe and cutting the pipe at the first predetermined length.

In a preferred embodiment, the step of extruding at least one pipe ofthe second predetermined length includes the steps of cooling the atleast one pipe and cutting the at least one pipe at the secondpredetermined length.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed embodiments will described with reference to theaccompanying drawings. Like pieces in different drawings carry the samenumber.

FIG. 1 is a flow chart of a preferred embodiment.

FIG. 2A is a side view of a template of a preferred embodiment.

FIG. 2B is a side view of a template of a preferred embodiment.

FIG. 2C is a side view of a template of a preferred embodiment.

FIG. 3A is a top view of a frame of a preferred embodiment.

FIG. 3B is a side view of a frame of a preferred embodiment.

FIG. 4 is a side view of a preferred embodiment.

FIG. 5A is a side view of a preferred embodiment.

FIG. 5B is an end view of a preferred embodiment.

FIG. 5C is a plan view of a preferred embodiment.

FIG. 6A is a side view of a preferred embodiment.

FIG. 6B is an end view of a preferred embodiment.

FIG. 6C is a plan view of a preferred embodiment.

FIG. 7A is an isometric view of a duct bank of a preferred embodiment.

FIG. 7B is a partial section view taken along line I-I of FIG. 7A of aduct bank of a preferred embodiment.

FIG. 8A is a computer architecture schematic of a controller system of apreferred embodiment.

FIG. 8B is a flowchart of a method executed by the controller system.

DETAILED DESCRIPTION

Referring to FIG. 1, a method for manufacturing a duct bank isdescribed. In a preferred embodiment, in step 1, a movable frame isprovided having a set of regularly spaced template supports. In step 2,a set of templates is provided, each including a set of holes in apattern. In step 3, the set of templates are loaded into the templatesupports. In step 4, the set of templates are positioned so that each ofthe sets of holes is aligned to form a set of coaxially aligned holes or“receivers” for the duct pipes. In step 5, the frame and the set ofadjusted templates is positioned adjacent a pipe extrusion machine, thepipe extrusion machine having an extrusion die, a cooling section, and acutter. In an optional step 6, a chosen receiver is positioned relativeto an x-y plane to be coaxial with the extrusion die. In step 7, a pipeof a first predetermined length is extruded into the receiver. Step 7includes the optional step of cooling the pipe. In step 8, the pipe iscut to a first predetermined length. In step 9, steps 6, 7 and 8 arerepeated until all receivers are full, thereby forming a duct bank. Theduct bank is banded in step 10 and removed from the frame in step 11.

Referring to FIGS. 2A, 2B, and 2C, examples of preferred embodiments ofthe templates are shown. Templates 101, 102, and 103 each have generallyrectangular hole pattern 104, 105, and 106, arranged in x-y plane 99.Each hole has a larger diameter than the diameter of the pipe to bereceived. In a preferred embodiment, the holes have a diameter about15-20% larger than that of the pipe. The diameter of the pipe and thenumber of holes, including the number of rows and columns, varyaccording to the desired duct bank to be assembled. Other geometricalpatterns, besides rectangular, may be employed.

In a preferred embodiment, the templates are generally flat having athickness of approximately ¾ inch. Other shapes and thicknesses may beemployed. In a preferred embodiment, templates 101, 102, and 103 aremade of plastic, such as HDPE, Delrin, or Teflon. Other durablematerials known in the art may be employed.

Referring to FIG. 3A, frame 200 includes rails 201 and 202. Angledmember 203 has first end 234 and second end 235. Angled member 204 hasfirst end 232 and second end 233. First end 234 of angled member 203attaches to rail 201. First end 232 of angled member 204 attaches torail 202. Second end 233 of angled member 204 attaches to second end 235of angled member 203. Cross members 205, 206, 207, 208, and 209 connectto rails 201 and 202. Hitch 231 attaches to angled members 203 and 204at second ends 233 and 235. Wheels 227 and 228 attach to rail 202.Wheels 229 and 230 attach to rail 201. Post 225 attaches to rail 202 andangled member 204 adjacent first end 232 of angled member 204 and rail202. Post 226 attaches to rail 201 and angled member 203 adjacent firstend 234 of angled member 203 and rail 201.

Referring to FIG. 3B, supports 210 and 211 attach to cross member 205.Supports 210 and 211 form slot 212. Slot 212 receives, supports, andorients template 130 generally perpendicularly with respect to rails 201and 202. Supports 213 and 214 attach to cross member 206. Supports 213and 214 form slot 215. Slot 215 receives, supports, and orients template131 generally perpendicularly with respect to rails 201 and 202.Supports 216 and 217 attach to cross member 207. Supports 216 and 217form slot 218. Slot 218 receives, supports, and orients template 132generally perpendicularly with respect to rails 201 and 202. Supports219 and 220 attach to cross member 208. Supports 219 and 220 form slot221. Slot 221 receives, supports, and orients template 133 generallyperpendicularly with respect to rails 201 and 202. Supports 222 and 223attach to cross member 209. Supports 222 and 223 form slot 224. Slot 224receives, supports, and orients template 134 generally perpendicularlywith respect to rails 201 and 202.

The distance between cross members 205, 206, 207, 208, and 209, andthereby the distance between loaded templates 130, 131, 132, 133, and134, is dependent upon the strength, the length, and the diameter of thedesired pipe to be used in the duct bank. In one preferred embodiment,the cross members are spaced evenly to support 40′ sections of pipe. Inanother embodiment, the cross members are spaced evenly to support 20′sections of pipe.

In a preferred embodiment, rails 201 and 202, angled members 203 and204, cross members 205, 206, 207, 208, and 209, and supports 225 and 226are made of steel. Other rigid and durable materials known in the artmay be employed.

In a preferred embodiment, supports 210, 211, 213, 214, 216, 217, 219,220, 222, and 223 are made of steel angle iron. Other rigid and durablematerials known in the art may be employed. In other embodiments thecross members can have different cross sections, such as box channeland/or triangular supports.

In a preferred embodiment, wheels 227, 228, 229, and 230 are castorwheels. Other wheel types known in the art may be employed.

Referring to FIG. 4, in one embodiment, proximal end 251 of frame 200 ispositioned adjacent extrusion system 300. Extrusion system 300 includesextruder 304, extrusion die 301 attached to extruder 304, coolingsection 302, aligned with extrusion die 301, and cutter 303, alignedwith cooling section 302. Each of templates 130, 131, 132, 133, and 134is identical, and includes a set of holes arranged in the same pattern.The sets of holes are aligned by adjusting the templates, one toanother, until the holes match the sets of aligned holes for receiversfor the pipes.

Pipes 450 and 451 are shown positioned in the set of holes of templates130, 131, 132, 133, and 134. Each pipe is cut to a predetermined length.The pipes can have different predetermined lengths. In one preferredembodiment, workers 801 and 811 manually transport pipe 452 from cutter303 and insert it into one of the set of coaxially aligned holes of thetemplates. Workers 801 and 811 repeatedly transport and insert each pipeinto the set of holes until each of the set of coaxially aligned holescontains a pipe.

The duct bank is then banded for transport. Banding includes the stepsof inserting blocks at chosen intervals between the pipes and betweenthe templates. Steel straps, as known in the art, are then positionedaround the duct bank and secured in other to prevent the templates andpipes from changing position during transport. The duct bank is thenlifted from the frame and transported to the jobsite for installation.

Referring to FIGS. 5A-5C, in another embodiment, proximal end 251 offrame 200 is positioned adjacent extrusion system 300. Extrusion system300 includes extruder 304, extrusion die 301 attached to extruder 304,cooling section 302 collinearly aligned with extrusion die 301, andcutter 303 collinearly aligned with cooling section 302. The holes oftemplates 130, 131, 132, 133, and 134. The position of the frame in thex-y plane is adjusted so as to coaxially align with extrusion die 301,cooling section 302, and cutter 303 with a set of collinear holes in thetemplates.

In this embodiment, frame 200 is horizontally and vertically positionedwith respect to extrusion system 300 by position system 700. Positionsystem 700 includes indexing tracks 701 and 702, winches 703, 704, 715and 750 connected to the frame by cables. The winches are typicallysupported overhead by attachment to beams 752 and 754. In a preferredembodiment, winches 703, 704, 715, and 750 are electric winches capableof lifting about 2,000 pounds. In one preferred embodiment, each winchis locally controlled with a drop switch (not shown). In anotherpreferred embodiment each winch is connected to a programmablecontroller.

Winches 703, 704, 715 and 750 are attached to the frame by a series ofcables or wire ropes. Winches 703, 704, 715 and 750 are movably attachedto track 701 and 702 through a rolling suspension system including a setof carriages 797, 799, 795, and 793 operatively attached to wheels 740,741, 762, 764, 738, 739, 766 and 768, respectively.

Winch 703 is attached to indexing track 701. Winch 703 is also attachedto main cable 705. Secondary cables 707 and 708 attach to main cable705. Hook 711 attaches to secondary cable 707. Hook 711 connects to eyehook 253. Eye hook 253 attaches to rail 202 of frame 200. Hook 712attaches to secondary cable 708. Hook 712 connects to eye hook 254. Eyehook 254 attaches to rail 202 of frame 200.

Winch 704 is attached to indexing track 702. Winch 704 is also attachedto main cable 706. Secondary cables 709 and 710 attach to main cable706. Hook 713 attaches to secondary cable 709. Hook 713 connects to eyehook 255. Eye hook 255 attaches to rail 202 of frame 200. Hook 714attaches to secondary cable 710. Hook 714 connects to eye hook 256. Eyehook 256 attaches to rail 202 of frame 200.

Winch 715 is attached to indexing track 701. Winch 715 is also attachedto main 768. Secondary cables 716 and 756 attach to main cable 759. Hook770 attaches to secondary cable 716. Hook 770 connects to eye hook 774attached to the frame. Hook 772 attaches to secondary cable 756. Hook772 connects to eye hook 776 connected to the frame.

Winch 750 is attached to indexing track 702. Winch 750 is also attachedto main cable 778. Secondary cables 758 and 760 attach to main cable778. Hook 780 attaches to secondary cable 758. Hook 780 connects to eyehook 784. Eye hook 784 is attached to the frame. Hook 782 attaches tosecondary cable 760. Hook 782 connects to eye hook 786. Eye hook 786 isconnected to the frame.

Winches 703, 704, 715 and 750 enable movement of frame 200 along y-axis743, thereby enabling positioning system 700 to position each hole ofgeometrical 106 at a set of predetermined positions along y-axis 743.

Linear motivators 790 and 794 are positioned at the respective ends ofindexing track 701. Linear motivator 790 is connected to a threadedreceiver incorporated into carriage 797 by threaded rod 798. Linearmotivator 794 is connected to a threaded receiver incorporated intocarriage 799 by threaded rod 796. A similar set of motivators 788 and792, threaded rods 789 and 791, and carriages are included in indexingtrack 702 which is connected to winches 704 and 750. Wheels 738, 739,740, and 741 roll within indexing track 701, and wheels 762, 764, 766and 768 roll within indexing track 702, thereby enabling movement offrame 200 along x-axis 742 and enabling position system 700 to positioneach hole of geometrical pattern 106 at a set of predetermined positionsalong x-axis 742. When activated, the linear motivators rotate thethreaded rods to move the carriages and the winches along an x-axis. Ina preferred embodiment, linear motivators 790 and 794 are electricmotors with the appropriate transmissions to rotate the threaded rods ata desirable slow speed. In one preferred embodiment, the motivators arecontrolled locally by a drop switch. In another preferred embodiment,the motivators are connected to and controlled by a programmablecontroller which positions the frame.

Referring to FIGS. 6A-6C, in another embodiment, proximal end 251 offrame 200 is positioned collinearly adjacent extrusion system 300.Extrusion system 300 includes extruder 304, extrusion die 301 attachedto extruder 304, cooling section 302 collinearly aligned with extrusiondie 301, and cutter 303 collinearly aligned with cooling section 302.The holes of templates 130, 131, 132, 133, and 134 coaxially align withextrusion die 301, cooling section 302, and cutter 303.

In this embodiment, frame 200 is horizontally and vertically positionedwith respect to extrusion machine 300 by position system 950. Positionsystem 950 includes indexing tracks 923 and 925 connected to a series ofhydraulic lifting pistons. Indexing tracks 923 and 925 support frame200. Indexing track 923 slidably engages with inside track 922. Insidetrack 922 attaches to piston rods 920 and 936. Piston rod 920 attachesto piston 951. Piston 951 slidably engages with cylinder 918. Piston rod936 attaches to piston 957. Piston 957 slidingly engages cylinder 935.

Indexing track 925 slidably engages with inside track 924. Inside track924 attaches to piston rods 921 and 812. Piston rod 921 attaches topiston 952. Piston 952 slidably engages with cylinder 919. Piston rod812 attaches to piston 808. Piston 808 slidingly engages with cylinder809. Position system 950 further includes piston rod 936 connected toinside track 922. Piston rod 936 further connects to piston 957. Piston957 slidably engages with cylinder 935.

Each of the cylinders is connected to hydraulic fluid line 930.Hydraulic fluid line 930 connects to pump 931. In one embodiment, pump931 is manually controlled by a foot switch. In another embodiment, pump931 connects to controller 933 with communication line 932. Controller933 connects to monitor 934 and keyboard 735 for data management andentry by an operator.

Linear motivator 802 is attached to outside track 923. Linear motivator802 includes pinion 806. Pinion 806 engages rack 1000 attached to insidetrack 922. Linear motivator 800 is attached to indexing track 925.Linear motivator 800 includes pinion 804 which engages rack 1002 ofinside track 924. In a preferred embodiment, the linear motivatorsinclude electric motors which rotate the pinions which thereby move theracks along the x-axis. In one preferred embodiment, the motivators arecontrolled locally using a drop switch. In another preferred embodiment,the motivators are connected to and controlled by a programmablecontroller which positions the frame.

The sliding engagement between inside track 922 and indexing track 923enables movement of frame 200 along the x-axis and moves the frame toposition the templates to predetermined positions along the x-axis.

Pressure from the hydraulic fluid against the pistons enables movementof frame 200 along y-axis 954 and moves the frame to position thetemplates to predetermined positions along the y-axis.

Referring to FIG. 8A, control system 1150 is described. Controller 1152,in a preferred embodiment, includes a programmable microcontroller or acomputer work station programmed with suitable programming to carry outmethod steps necessary to move the x motivators and the y motivators topredetermined positions in order to move the frame to a predeterminedlocation in the x-y plane. Controller 1152 is connected to x positionmotivators 1154, y position motivators 1156 and stop sensor 1158.

In a preferred embodiment, stop sensor 1158 is a simple mechanical limitswitch, fixed in a position of axial alignment with the extruder and ina position to sense contact with the end of the pipe as it is completelyinserted in the axially aligned holes or receivers. In anotherembodiment, the limit switch can be an optical sensor and transmitterpair connected to the controller.

Referring to FIG. 8B, the method 850 is described that is executed bythe program resident on controller 1152.

At step 852, the program starts. At step 854, input is received from theoperator regarding a maximum number columns in the template (“MAXX”) andthe maximum number of rows in the template (“MAXY”). At step 855, inputis received which identifies each unique location in the x-y plane of anaxis corresponding to the center of a particular receiver. The locatorsare numbered in a sequence of rows and columns each having an x-yaddress.

At step 856, the program then initiates and sets a variable x to 1, andinitiates and sets a variable y to 1.

At step 857, the controller sends signals to the x position motivators1154 and y position motivators 1156 sufficient to locate the frame andassociated templates to the x=1, y=1 position corresponding to the firstaxis physical location.

At step 858, the controller waits for a signal from stop sensor 1158indicating that a pipe has been inserted. At step 860, the controllercompares the x location to the variable MAXX. If the variables are notequal, the program moves to step 862 and increments the x value by 1 andthen proceeds to step 863. At step 863 the controller sends signals tothe x and y motivators sufficient to physically move the frame to its xposition. The new position coaxially locates the next receiver in orderwith the extruder and extrusion die. The program then returns to step858. If the variables are equal, then the program proceeds to step 864and resets the value of x to 1. At step 865, the controller send signalsto the x motivators sufficient to return them to their original xposition thereby aligning the original receiver with the extruder.

At step 866, the value of y is incremented by 1. At step 868, theprogram compares the value of y to MAXY. If the position of y is notgreater than MAXY, then the program returns to step 869 where thecontroller send signals to the y position motivators sufficient toadvance the frame to the next y position. The next y positioncorresponds to the row of empty receivers above the first row. Theprogram then returns to step 858. If the value of y is greater thanMAXY, then the program proceeds to step 870 and ends.

In a preferred embodiment the receivers are filled in order from left toright and bottom to top in order to increase duct bank stability.However, other orders of x-y positions can be used with success.

The program in a preferred embodiment is written in a basic interpretivelanguage such as Basic or FORTRAN. However, other languages may beemployed. In a preferred embodiment, the program is stored in physicalmemory at the controller. However, in other embodiments the program maybe stored on a computer network connected to the controller on aremovable permanent memory accessed by the controller.

Referring to FIG. 7A, by way of example, after assembly, duct bank 400comprises pipes 401, 402, 403, 404, 405, 406, 407, 408, and 409 insertedthrough templates 130, 131, 132, 133, and 134.

In a preferred embodiment, pipes 401, 402, 403, 404, 405, 406, 407, 408,and 409 are made of polyvinyl chloride (PVC). Other materials known inthe art may be employed.

Band 475 surrounds pipes 402, 405, and 408. Blocks 417 and 418 positionwithin duct bank 400 and held in position with band 475. Block 417 isheld adjacent pipes 402, 405, and 408 by band 475. Block 418 is heldadjacent pipes 402, 405, and 408, opposite block 417 by band 475. Band410 surrounds pipes 401, 402, 403, 404, 406, 407, 408, and 409. Blocks415 and 416 position on the outer sides of duet bank 400 and maintainedin position by band 410. Block 415 is held adjacent pipes 403, 406, and409 by band 410. Block 416 is held adjacent pipes 401, 404, and 407 byband 410.

Referring to FIGS. 7A and 7B, by way of example, band 412 surroundspipes 402, 405, and 408. Blocks 419 and 420 position within duct bank400 and held in position with band 412. Block 419 is held adjacent pipes402, 405, and 408 by band 412. Block 420 is held adjacent pipes 402,405, and 408, opposite block 419 by band 412. Band 411 surrounds pipes401, 402, 403, 404, 406, 407, 408, and 409. Blocks 413 and 414 positionon the outer sides of duct bank 400 and maintained in position by band411. Block 413 is held adjacent pipes 403, 406, and 409. Block 414 isheld adjacent pipes 401, 404, and 407 by band 411.

The position of bands 410, 411, 412 and 475 and the distance betweeneach band is dependent upon the length, the strength, and the diameterof pipe to be used in duct bank 400, and the height and the width ofduct bank 400. Further, the number of bands and blocks employed variesand is dependent upon the length, the strength, and the diameter of pipeto be used in duct bank 400, and the height and the width of duct bank400.

In a preferred embodiment, bands 410, 411, 412 and 475 are made ofpolyester. Other materials known in the art may be employed.

In a preferred embodiment, blocks 413, 414, 415, 416, 417, 418, 419, and420 are made of wood. Other durable materials known in the art may beemployed.

It will be appreciated by those skilled in the art that modificationscan be made to the embodiments disclosed and remain within the inventiveconcept. Therefore, this invention is not limited to the specificembodiments disclosed, but is intended to cover changes within the scopeand spirit of the claims.

1. A method for manufacturing a duct bank utilizing a set of templates,the templates having hole patterns, and an extruder having an extrusiondie with an axis, comprising: providing a movable frame with a set oftemplate supports; loading the set of templates into the templatesupports; adjusting the hole patterns to form a set of coaxial receiverholes; positioning the frame adjacent the extruder; sequentiallyextruding and inserting a set of duct pipes into the set of coaxialreceiver holes; whereby the duct bank is formed.
 2. The method of claim1, further including the step of removing the duct bank from the movableframe.
 3. The method of claim 1, further comprising the step of securingthe set of duct pipes in the set of receiver holes.
 4. The method ofclaim 1, wherein the step of sequentially extruding and insertingfurther comprises the steps of: cooling the set of duct pipes; and,cutting the set of duct pipes to a first predetermined length.
 5. Themethod of claim 1, wherein the step of sequentially extruding andinserting includes the further steps of: indexing the set of coaxialreceiver holes to an x-position; and, indexing the set of coaxialreceiver holes to a y-position.
 6. A method for manufacturing a ductbank comprising the steps of: providing a frame; providing a set oftemplates, the set of templates having a set of patterned of holes;loading the set of templates into the frame; arranging the set ofpatterned holes to form a set of receivers; positioning the set ofreceivers adjacent an extrusion machine; extruding a pipe; cutting thepipe to a predetermined length; placing the pipe into a receiver of theset of receivers; and, repeating the steps of extruding, cutting andplacing for each receiver of the set of receivers, thereby completingthe duct bank.
 7. The method for manufacturing a duct bank of claim 6,wherein the step of extruding includes the further step of: cooling thepipe.
 8. The method of claim 6 further comprising the step of aligning areceiver of the set of receivers with an extrusion die of the extrusionmachine.
 9. The method of claim 8 further comprising the steps of:providing a means for moving the frame in a y direction; providing ameans for moving the frame in an x-direction; and, moving the frame,utilizing the means for moving the frame in an x direction and the meansfor moving the frame in a y direction, into a predetermined x-yposition.
 10. An apparatus for fabrication of a duct bank from anextrusion machine, comprising: a moveable frame, adjacent the extrusionmachine, having a set of support members; a set of templates, having aplurality of holes, supported by the support members; the plurality ofholes forming a set of receivers; and, whereby the extrusion machineextrudes a pipe for insertion each receiver of the set of receivers tofabricate the duct bank.
 11. The apparatus of claim 10 furthercomprising: an extrusion die attached to the extrusion machine; a ydirectional carriage and an x directional carriage supporting the frame;and, a means for axially aligning each receiver of the set of receiverswith the extrusion die utilizing the x directional carriage and the ydirectional carriage.
 12. The apparatus of claim 10, wherein thereceivers form a rectangular geometric pattern.
 13. The apparatus ofclaim 10 wherein the means for axially aligning further comprises: acomputer; an x directional motivator, attached to the x directionalcarriage and operatively connected to the controller; a y directionalmotivator, attached to the y directional carriage and operativelyconnected to the controller; a limit switch, located at a pipe stopposition adjacent the frame; and, the controller programmed to: activatethe x directional motivator to position the set of receivers in a firstx-y position; acknowledge a signal from the limit switch indicatinginsertion of the pipe into a receiver of the set of receivers; and,activate the y directional motivator to position the set of receivers ina second x-y position.
 14. The apparatus of claim 13 wherein the xdirectional motivator comprises at least one threaded drive.
 15. Theapparatus of claim 13 wherein the y directional motivator comprises atleast one winch, connected to the frame by at least one cable.
 16. Theapparatus of claim 13 wherein the x directional motivator comprises atleast one rack and pinion mechanism.
 17. The apparatus of claim 13wherein the y directional motivator comprises at least one hydraulicpiston.
 18. The apparatus of claim 10 wherein the movable frame furthercomprises a pair of channel members connected by the set of supportmembers and supported by a set of castors.
 19. The apparatus of claim 10each of the support members is comprised of a slot formed by one of thegroup of angle braces, channel braces and triangle braces.
 20. Anapparatus for fabrication of a duct bank from duct pipe from anextrusion machine including an extrusion die and a cooling system and acutting system comprising: a frame, having a set of parallel slots,adjacent the cutting system; a movable x positioning system supportingthe frame; a movable y positioning system supporting the frame; a pipeinsertion indicator; a controller, operatively connected to the movablex position system, the movable y position systems and the pipe insertionindicator; a set of planar rectangular templates, each template having apattern of holes; each template in the set of planar rectangulartemplates rigidly positioned in the set of planar slots, whereby thepattern of holes forms a set of receivers, each receiver of the set ofreceivers having an axis; the controller programmed to: index each axisof each receiver of the set of receivers to a set of unique x-ypositions; activate the movable x positioning system and the ypositioning system to coaxially locate a first axis of a first receiverof the set of receivers with a first unique x-y position; receive asignal from the pipe insertion indicator indicating pipe insertion;repeating the activate and receive steps for each unique x-y position ofthe set of unique positions; whereby the duct bank is fabricated.